Foam in the body

Hi all,
Thanks for the info on rust treatment. Another question, while I was
removing body putty from the right rear, just below the left rear window and
behind the half moon vent, I opened a hole about 6 inches by 8 inches and
found alot of rust. So much rust that I had to dig all of the foam out of
the body. After much work and knocking the skin off all my knuckles, I was
able to get it all out. Then I found that the rust goes thru the inside
metal and was just covered up by the headliner! Well, my question is: how
important is the foam in the body, do I need to replace it? The companion
question concerns the air duct to the engine compartment, it is rusted away
and the air will most likely just flow to the rear vents and not be directed
into the engine compartment. Can I insert a hose into this void running from
the half moon vent to the outlet at the top of the engine compartment? If I
do that I suppose I could fill the void with foam if it is necessary.
H-S-F

help-slip-franklin wrote:

> Hi all,
> Thanks for the info on rust treatment. Another question, while I was
> removing body putty from the right rear, just below the left rear window and
> behind the half moon vent, I opened a hole about 6 inches by 8 inches and
> found alot of rust. So much rust that I had to dig all of the foam out of
> the body. After much work and knocking the skin off all my knuckles, I was
> able to get it all out. Then I found that the rust goes thru the inside
> metal and was just covered up by the headliner! Well, my question is: how
> important is the foam in the body, do I need to replace it? The companion
> question concerns the air duct to the engine compartment, it is rusted away
> and the air will most likely just flow to the rear vents and not be directed
> into the engine compartment. Can I insert a hose into this void running from
> the half moon vent to the outlet at the top of the engine compartment? If I
> do that I suppose I could fill the void with foam if it is necessary.
> H-S-F
>
>
>
Yeah, common problem. <sigh>

The half moons are not for the engine; they take out cabin air
thru the plastic "grilles" in the headliner.

The foam (or something) is needed to keep engine bay vapors
from getting to the interior.

And if one side is rusted, the other is sure to be too.
The left side contains the Main harness, so you gotta be
careful working around it.

Speedy Jim
http://www.nls.net/mp/volks/

Speedy Jim wrote:
> help-slip-franklin wrote:
>
> > Hi all,
> > Thanks for the info on rust treatment. Another question, while I was
> > removing body putty from the right rear, just below the left rear window and
> > behind the half moon vent, I opened a hole about 6 inches by 8 inches and
> > found alot of rust. So much rust that I had to dig all of the foam out of
> > the body. After much work and knocking the skin off all my knuckles, I was
> > able to get it all out. Then I found that the rust goes thru the inside
> > metal and was just covered up by the headliner! Well, my question is: how
> > important is the foam in the body, do I need to replace it? The companion
> > question concerns the air duct to the engine compartment, it is rusted away
> > and the air will most likely just flow to the rear vents and not be directed
> > into the engine compartment. Can I insert a hose into this void running from
> > the half moon vent to the outlet at the top of the engine compartment? If I
> > do that I suppose I could fill the void with foam if it is necessary.
> > H-S-F
> >
> >
> >
> Yeah, common problem. <sigh>
>
> The half moons are not for the engine; they take out cabin air
> thru the plastic "grilles" in the headliner.
>
> The foam (or something) is needed to keep engine bay vapors
> from getting to the interior.
>
> And if one side is rusted, the other is sure to be too.
> The left side contains the Main harness, so you gotta be
> careful working around it.
>
> Speedy Jim
> http://www.nls.net/mp/volks/

HSF,
Had the same problem on my '76 bug. Removed all the old foam. Treated /
removed the rusted areas. Painted the metal. Tried to live with the
straight shot from the engine compartment but the 1776cc engine was too
noisy and as Speedy Jim said it caused engine fumes and smells to enter
the passenger compartment. Solved the problem by reinstalling some of
that expanding foam /insullation that's in a spray can. With the metal
treated with paint on the inside, the rust problems associated with the
foam getting wet is just about eliminated.

Wild Bill Tucker
Pensacola, Fl
http://home.bellsouth.net/p/PWP-rareair

Wild Bill wrote:
> Speedy Jim wrote:
> > help-slip-franklin wrote:
> >
> > > Hi all,
> > > Thanks for the info on rust treatment. Another question, while I was
> > > removing body putty from the right rear, just below the left rear window and
> > > behind the half moon vent, I opened a hole about 6 inches by 8 inches and
> > > found alot of rust. So much rust that I had to dig all of the foam out of
> > > the body. After much work and knocking the skin off all my knuckles, I was
> > > able to get it all out. Then I found that the rust goes thru the inside
> > > metal and was just covered up by the headliner! Well, my question is: how
> > > important is the foam in the body, do I need to replace it? The companion
> > > question concerns the air duct to the engine compartment, it is rusted away
> > > and the air will most likely just flow to the rear vents and not be directed
> > > into the engine compartment. Can I insert a hose into this void running from
> > > the half moon vent to the outlet at the top of the engine compartment? If I
> > > do that I suppose I could fill the void with foam if it is necessary.
> > > H-S-F
> > >
> > >
> > >
> > Yeah, common problem. <sigh>
> >
> > The half moons are not for the engine; they take out cabin air
> > thru the plastic "grilles" in the headliner.
> >
> > The foam (or something) is needed to keep engine bay vapors
> > from getting to the interior.
> >
> > And if one side is rusted, the other is sure to be too.
> > The left side contains the Main harness, so you gotta be
> > careful working around it.
> >
> > Speedy Jim
> > http://www.nls.net/mp/volks/
>
> HSF,
> Had the same problem on my '76 bug. Removed all the old foam. Treated /
> removed the rusted areas. Painted the metal. Tried to live with the
> straight shot from the engine compartment but the 1776cc engine was too
> noisy and as Speedy Jim said it caused engine fumes and smells to enter
> the passenger compartment. Solved the problem by reinstalling some of
> that expanding foam /insullation that's in a spray can. With the metal
> treated with paint on the inside, the rust problems associated with the
> foam getting wet is just about eliminated.
>
> Wild Bill Tucker
> Pensacola, Fl
> http://home.bellsouth.net/p/PWP-rareair

I have a 72 as well and it has rusted through under the half moon - a
small spot, around the size of a 1/2 dollar. I think the foam has been
removed by the previous owner and he's tried to 'fix' that problem with
bondo, from the looks of it.

I don't quite understand the purpose of that foam, if you fill that
whole area with it.
Can't you just weld that area closed, if that is the case?

Remco

OK, that answers my question, I'm going to treat all the metal then refill
the area with foam; but... how do I ensure that I don't fill the area that
needs to be open to the cabin area behind the headliner and end up
preventing the air exchange? BTW, Speedy, you are right about the other
side, I just have not gotten to that side in my work yet, but the old body
filler is cracked there too.
Thanks
H-S-F

help-slip-franklin wrote:
> OK, that answers my question, I'm going to treat all the metal then
> refill the area with foam; but... how do I ensure that I don't fill
> the area that needs to be open to the cabin area behind the headliner
> and end up preventing the air exchange?

The Bug got along for something like twenty years without those vents. Worry
not.

You might want to look into swing-out rear windows. Very kool, more
effective.